Power source system with remotely configurable power source

ABSTRACT

A power source system including plural power sources, wherein each of the plural power sources is adapted to provide a configurable power output to an implement, and wherein each of the plural power sources has an onboard controller; a central controller that is remote from the plural power sources; the central controller being in communication with respective onboard controllers via one or more networks, the central controller being adapted to communicate a signal to at least one onboard controller to selectively alter an operating condition of an associated power source.

TECHNICAL FIELD

The present embodiments relate generally to a power source system. Moreparticularly, the present embodiments relate to a power source systemthat includes a power source connected via network to a centralcontroller that is remote from the power source and communicates asignal adapted to alter an operating parameter of the power source.

SUMMARY

The following presents a simplified summary of the invention in order toprovide a basic understanding of some aspects of the invention. Thissummary is not an extensive overview of the invention. It is notintended to identify key or critical elements of the invention or todelineate the scope of the invention. Its sole purpose is to presentsome concepts of the invention in a simplified form as a prelude to themore detailed description that is presented later.

In accordance with one embodiment a power source system includes pluralpower sources, wherein each of the plural power sources is adapted toprovide a configurable power output to an implement, and wherein each ofthe plural power sources has an onboard controller; a central controllerthat is remote from the plural power sources; the central controllerbeing in communication with respective onboard controllers via one ormore networks, the central controller being adapted to communicate asignal to at least one onboard controller to selectively alter anoperating condition of an associated power source. In one example, thesignal instructs the onboard controller to deactivate power to theimplement or deactivate the associated power source to prevent operationthereof. In another example, the signal configures the onboardcontroller to set a maximum available power output of the associatedpower source to a configured output level. The configured output levelmay be a selected amperage, voltage, wattage or other unit ofmeasurement commonly referred to in a given application or industry. Forexample, in a welding application it is common to refer to power interms of an amperage. For example, the configurable power may beexpressed as 100 amp, 300 amp, 500 amp and so on. These values areprovided as examples. It will be understood that any value between 0 andthe maximum available power for a given power source may be used.

According to another exemplary embodiment, the onboard controller isadapted to monitor an emission level of the associated power source andcommunicate emission information to the central controller; and whereinthe central controller receives the emission information from theonboard controller and a maximum available power output of theassociated power source based on the emission information received.

According to another exemplary embodiment the implement is a weldingtorch. In another exemplary embodiment, the implement is a cuttingtorch.

According to another exemplary embodiment at least one of the pluralpower sources includes an accessory, and wherein the operating conditionincludes an activation state of the accessory.

According to another exemplary embodiment, the onboard controllerincludes a sensor that tracks a limiting condition and communicates avalue of the limiting condition to the central controller, and whereinupon detection of the value of the limiting condition reaching aselected limit, the central controller alters the operating condition.According to a further example, the limiting condition includes at leastone of an operating time limit, a geographical limit, an emissionslimit, a pollution limit, a noise limit, a network connectivity limit,and a time limit.

Another exemplary embodiment includes power source system includingpower source in communication with a power source network, wherein eachof power source in the network has an active mode where power isprovided to an implement and an idle mode where no power is beingprovided to the implement; a central controller in communication withthe power source network, the central controller being remote from thepower source and in communication with the power source via the powersource network, wherein the central controller monitors a time period ofoperation for the power source, wherein the time period of operationincludes active mode time but excludes idle mode time, and wherein thecentral controller deactivates the power source when a respective timeperiod of operation exceeds an authorized period of operation.

According to another exemplary embodiment, the implement is a weldingtorch.

According to another exemplary embodiment, the central controllercalculates a charge based on the time period of operation. According toa further embodiment, the power source includes a payment component,wherein the central controller communicates with the payment componentand wherein the central controller includes a maximum period ofoperation for each of the plural power sources and deactivates aselected power source when the time period of operation is reached.According to a further example, the central controller is adapted toallocate an additional maximum period of operation or an extension ofthe maximum period of operation upon receiving a selected payment fromthe means for payment.

Another exemplary embodiment includes power source system including aprocessor; a communications interface; and a computer-readable storagemedium having stored thereon computer-executable instructions that, whenexecuted by the processor, configure the processor to: receive, via thecommunications interface, operational information from an onboardcontroller of a power source adapted to provide a configurable poweroutput to an implement; and communicate a signal to the onboardcontroller to alter an operating state of the power source based atleast in part on the operational information. According to on example,the signal instructs the onboard controller to deactivate power to theimplement or deactivate the associated power source to prevent operationthereof. According to another example, the signal configures the onboardcontroller to set a maximum available power output of the associatedpower source to a configured output level.

Another exemplary embodiment includes power source system includingplural power sources, wherein each of the plural power sources isadapted to provide a configurable power output to an implement, andwherein each of the plural power sources has an onboard controller; acentral controller that is remote from the plural power sources and incommunication with each power source, wherein the central controllertracks a location of each of the plural power sources and wherein thecentral controller receives geographic based alert information; whereinthe central controller sets a parameter including at least one of theconfigurable power output, an engine operating limit, and an accessoryoperating limit of each power source based on the geographic based alertinformation. According to one example, the geographic based alertinformation includes ozone action alerts. According to another example,the geographic based alert information includes a noise restriction.According to a further example, the geographic based alert includes apermitted geography limit.

The following description and the annexed drawings set forth in detailcertain illustrative aspects of the invention. These aspects areindicative, however, of but a few of the various ways in which theprinciples of the invention may be employed and the present invention isintended to include all such aspects and their equivalents. Otheradvantages and novel features of the invention will become apparent fromthe following detailed description of the invention when considered inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram illustrating a power source systemaccording to an embodiment.

FIG. 2 is a schematic block diagram illustrating a power source systemaccording to an embodiment.

FIG. 3 is a schematic block diagram illustrating a power source systemaccording to an embodiment.

FIG. 4 is a power source according to an embodiment.

FIG. 5 is a schematic diagram of a power source system according to anembodiment depicting details of a geographic location component on apower source.

FIG. 6 is a schematic block diagram of a power source system accordingto an embodiment depicting details of a payment component.

FIG. 7 is a schematic block diagram according to an embodiment showingdetails of a remote device that communicates with a central controllerin the power source system.

FIG. 8 is an operational flow diagram showing a method of operating thepower source system according to an embodiment.

FIG. 9 is an operational flow diagram showing a method of operating thepower source system according to an embodiment.

DESCRIPTION OF THE INVENTION

The present invention is now described with reference to the drawings,wherein like reference numerals are used to refer to like elementsthroughout. In the following description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding of the present invention. It may be evident to one skilledin the art that the present invention may be practiced without thesespecific details. In other instances, well-known structures and devicesare shown in block diagram form in order to facilitate description ofthe present invention.

As used in this application, the term “remote” is defined as physicallyseparated from an object by a distance. For example, a controller isdescribed as being remote from a power source to indicate that they arenot physically connected to each other.

As used in this application, the term “component” is intended to referto a electronic and/or computer-related entity, either hardware, acombination of hardware and software, software, or software inexecution. For example, a component may be, but is not limited to being,a process running on a processor, a processor, an object, an executable,a thread of execution, a program, and a computer. By way ofillustration, both an application running on a server and the server canbe a component.

In general, the following specification discusses the remote control ofplural power sources connected to a controller through a network. Itwill be understood that the power source may be used in a variety ofapplications that require electrical power including but not limited tovehicles, power tools, portable generators, cement mixers, welding,heating, soldering, brazing, and cutting applications. To that end,reference to a power source should not be considered limiting as to aparticular application or implement powered by the power source. Thefollowing description will proceed with reference to a power source usedin welding and cutting, but this should not be viewed as limiting. Theuse of the terms welding and cutting is for sake of simplicity andshould be understood to include welding, cutting, heating, soldering,and brazing.

One possible application for this remote control of plural power sourcesis in connection with rental applications or other fleet operations ofpower sources. For example, rental companies rent welding and cuttingequipment including power sources. These power sources may include powersources that must be connected to a power supply, portable power sourcesthat contain their own power supply, such as an engine driven generatoror energy storage device, or hybrid systems that combine types of powersupplies. In renting such equipment, different welding or cuttingprocesses may require different amounts of power so that the rentalcompany may stock several models to accommodate various power needs. Forexample, rental companies often stock power supplies that providedifferent maximum amperage, such as 100 amp, 300 amp, or 500 ampsupplies. The power supplies may also be stocked to include differenttypes of welding or cutting operations. For example, in the weldingcontext, different welding power supplies may be required to providemultiple welding modes, such as pulse, surface tension transfer (STT)and the like. Again to accommodate varying needs among users, multiplepower supplies may need to be stocked. The same holds true in anon-rental context where plural welding power supplies are stocked foruse by employees or contractors to accommodate varying needs for powersupplies.

In addition, users may want power sources with built in accessories,such as, pumps or air compressors. It is difficult to predict the demandfor various power levels or accessories and at times, power sources withgreater capacity than required or accessories that the user does notneed may be rented at a lower rate. Also, it is common that an accessorymay be used infrequently by the user or the maximum power level onlyused for a shorter period of operation. To provide more flexibility tothe user, the invention contemplates providing central control to allowthe user to select and/or pay for only the features and power level thatthey need, and allow them to alter the power level or available featuresremotely from the rental site or other source. The flexibility may alsobe used by the user to provide a one size fits all option in terms ofpurchasing power sources according to the invention and using the remotecontrol feature to impose limits on operation, available features, andaccessories to customize the setup of the power source based on theusers' needs or to conform the power source to the terms of the rentalcontract or limits on operation imposed by outside factors. Outsidefactors may include environmental factors such as ozone alerts, emissionlevel restrictions in a particular geographic location, noiserestrictions, and the like. Finally, the system described herein may beused to deactivate or prevent operation of the power source from aremote location. This remote deactivation may be dictated by the termsof the rental agreement including but not limited to agreed to timelimits, or when operation outside of an agreed to geographic area occursor when a user repeatedly attempts to use the power source outside ofthe terms of the agreement or tampers with the power source.Deactivation may be temporary allowing the user to reactivate theequipment by satisfying a condition, such as paying for more time orreturning the welder to a permitted geographical location. While thedescription will proceed with the example of a power source for weldingor cutting operations, it will be understood that the control schemeutilized may be expanded to include other commonly rented goodsincluding vehicles, air compressors, cement mixers, and power toolspowered by a power source.

The best mode for carrying out the invention will now be described forthe purposes of illustrating the best mode known to the applicant at thetime of the filing of this patent application. The examples and figuresare illustrative only and not meant to limit the invention, which ismeasured by the scope and spirit of the claims. Referring now to thedrawings, wherein the showings are for the purpose of illustrating anexemplary embodiment of the invention only and not for the purpose oflimiting same, FIG. 1 illustrates a schematic block diagram of anexemplary embodiment of a power source system, generally indicated bythe number 100. System 100 includes a central controller 110 that isconnected to a network 120. The system 100 also includes one or morepower source 130 that is connected to central controller 110 by network120. As shown in FIG. 2, it is contemplated that system may include acentral controller 130 that is connected to plural power sources 130 (afirst power source, second power source . . . nth power source). Withfurther reference to FIG. 3, the power sources 130 may be used toperform a variety of applications, as discussed in more detail herein.FIG. 3 shows, for example, a first power source may be used in a cuttingapplication, a second may be used to perform stick welding and stillanother power source may be used in a moving platform weldingapplication. Each power source 130 is connected to central controller110 via network 120 as described more completely below.

With reference to FIG. 1, system 100 further includes an implement 140that is connected to one of the power sources 130 to perform anoperation 150. Implement 140 may be any vehicle, tool, accessory orother object that obtains power from power source 130. In a weldingapplication, implement 140 may include a welding torch 160 that useselectrical power from the power source to perform a welding operationincluding but not limited to heating, soldering, brazing, arc welding orlaser welding. Implement 140 may include related equipment such as aconsumable feeder, generally indicated at 145, such as a wire feeder forMIG or TIG welding or a stick feeder for stick welding. In weldingapplications where the welding torch 160 is mounted on a moving platform170 (FIG. 3), often referred to as a tractor or robot, that is alsopowered by the same power source 130, implement 140 may include thisequipment 170 as well. Plasma or laser cutting applications are similarin that implement 140 may include a cutting torch 175 that useselectrical energy from power source 130 to perform a cutting operationrather than a welding operation.

Power source 130 can be any suitable power source including a powersource that derives power from an outlet source 176 (FIG. 3), a batterysource or other energy storage device 177 (FIG. 6), an engine powersource 178 (FIG. 6), or combinations thereof including hybridcombinations that include an engine driven power source combined with abattery source to back up or supplement the power from the engine drivensource (FIG. 6). In a rental context, a variety of power sources 130 mayform part of the rental fleet F such that multiple types of powersources may comprise the plural power sources available for rental. Forexample, an engine driven, battery driven or combination of engine andbattery driven power source may be used in applications where grid poweror outlet power is not available. Alternatively, the same rental fleetmay include outlet power sources to be used in locations where gridpower is available or generator power is used to provide an outletsupply for the power source.

With reference to FIG. 1, in an arc welding application, a weldingcircuit path 105 runs from power source 130 through a welding cable 180to welding torch 160, through workpiece WP and/or to workpiece connector190, and back through welding cable 180 to power source 130. Duringoperation, electrical current runs through welding circuit path 105 as avoltage is applied to welding circuit path 105. In accordance with anexemplary embodiment, welding cable 180 comprises a coaxial cableassembly. In accordance with another embodiment, welding cable 180comprises a first cable length running from welder power source 130 towelding torch 160, and a second cable length running from workpiececonnector 190 to welder power source 130.

FIG. 4 depicts an embodiment of a system 100 used in a welding orcutting application. The system 100 includes a power source 130 having ahousing 112 which encloses the internal components of the power source130. Optionally, power source 130 includes a loading eyehook 114 and/orfork recesses. The loading eyehook 114 and the fork recesses facilitatethe portability of the power source 130. Optionally, a handle and/orwheels may be provided to further facilitate mobility. The housing 112also includes one or more access panel 118. Access panel 118 providesaccess to the internal components of the welding type device 100including, for example, an energy storage device suitable for providingwelding type power, such as a DC power source including but not limitedto a battery, capacitor or kinetic energy storage device. An end panelincludes a louvered opening 119 to allow for air flow through thehousing 112.

The housing 112 of power source shown in FIG. 4 also houses an internalcombustion engine. The engine is operatively coupled with exhaust port Pand fuel port 132 that protrude through the housing 112. The exhaustport P extends above the top panel 122 of the housing 112 and directsexhaust emissions away from power source 130. The fuel port 132preferably does not extend beyond the top panel 122 or side panel 124.Such a construction protects the fuel port 132 from damage duringtransportation and operation of the power source 130.

System 100 includes a processor 125 that evaluates a portion of datacollected by at least one power source 130. Processor 125 ascertains aparameter related to power source 130. Processor 125 enables a parameterfrom one welder power source in an environment on a first network to beutilized with at least one of another welder power source in theenvironment on the first network, another welder power source in theenvironment on a second network, or another welder power source inanother environment. Moreover, processor 125 can implement a parametercollected with a suitable component or device utilized in a weldingprocess (e.g., wire feeder, power source, among others). Processor 125may also obtain parameters from an onboard controller 200 associatedwith power source 130. As schematically shown in FIG. 5, onboardcontroller 200 may include a communications interface 250 thatcommunicates with a global communications network 300 to provide ageographic position signal 215 selectively communicated from onboardcontroller 200 to processor 125.

Processor 125 can be local or remote in comparison to power source 130.For instance, processor 125 can be a stand-alone component, incorporatedinto power source 130, or it may be provided remote from power source130. Processor 125, may be incorporated into a computing platform (e.g.,remote platform, local platform, cloud platform, software-as-a-service(SaaS) platform, among others).

In one embodiment, processor(s) 125 is a computer operable to executethe disclosed methodologies and processes, including methods describedherein. To provide additional context for various aspects of the presentinvention, the following discussion is intended to provide a brief,general description of a suitable computing environment in which thevarious aspects of the present invention may be implemented. While theinvention has been described above in the general context ofcomputer-executable instructions that may run on one or more computers,those skilled in the art will recognize that the invention also may beimplemented in combination with other program modules and/or as acombination of hardware and/or software. Generally, program modulesinclude routines, programs, components, data structures, etc., thatperform particular tasks or implement particular abstract data types.

Moreover, those skilled in the art will appreciate that the inventivemethods may be practiced with other computer system configurations,including single-processor or multiprocessor computer systems,minicomputers, mainframe computers, as well as personal computers,hand-held computing devices, microprocessor-based or programmableconsumer electronics, and the like, each of which may be operativelycoupled to one or more associated devices. The illustrated aspects ofthe invention may also be practiced in distributed computingenvironments where certain tasks are performed by remote processingdevices that are linked through a communications network. In adistributed computing environment, program modules may be located inboth local and remote memory storage devices. For instance, a remotedatabase, a local database, a cloud-computing platform, a clouddatabase, or a combination thereof can be utilized with processor 125.

The processor 125 can utilize an exemplary environment for implementingvarious aspects of the invention including a computer, wherein thecomputer includes a processing unit, a system memory and a system bus.The system bus couples system components including, but not limited tothe system memory to the processing unit. The processing unit may be anyof various commercially available processors. Dual microprocessors andother multi-processor architectures also can be employed as theprocessing unit.

The system bus can be any of several types of bus structure including amemory bus or memory controller, a peripheral bus and a local bus usingany of a variety of commercially available bus architectures. The systemmemory can include read only memory (ROM) and random access memory(RAM). A basic input/output system (BIOS), containing the basic routinesthat help to transfer information between elements within processor 125,such as during start-up, is stored in the ROM.

Processor 125 can further include a hard disk drive, a magnetic diskdrive, e.g., to read from or write to a removable disk, and an opticaldisk drive, e.g., for reading a CD-ROM disk or to read from or write toother optical media. Processor 125 can include at least some form ofcomputer readable medium, generally indicated at 126. Computer readablemedia 126 can be any available media that can be accessed by thecomputer. By way of example, and not limitation, computer readable media126 may comprise computer storage media and communication media.Computer storage medium 126 includes volatile and nonvolatile, removableand non-removable media implemented in any method or technology forstorage of information such as computer readable instructions, datastructures, program modules or other data. Computer storage medium 126includes, but is not limited to, RAM, ROM, EEPROM, flash memory or othermemory technology, CD-ROM, digital versatile disks (DVD) or othermagnetic storage devices, or any other medium which can be used to storethe desired information and which can be accessed by processor 125.

Communication media typically embodies computer readable instructions,data structures, program modules or other data in a modulated datasignal such as a carrier wave or other transport mechanism and includesany information delivery media. The term “modulated data signal” means asignal that has one or more of its characteristics set or changed insuch a manner as to encode information in the signal. By way of example,and not limitation, communication media includes wired media such as awired network or direct-wired connection, and wireless media such asacoustic, Radio Frequency (RF), Near Field Communications (NFC), RadioFrequency Identification (RFID), infrared, and/or other wireless media.Combinations of any of the above should also be included within thescope of computer readable media.

A number of program modules may be stored in the drives and RAM,including an operating system, one or more application programs, otherprogram modules, and program data. The operating system in processor 125can be any of a number of commercially available operating systems.

In addition, a user may enter commands and information into the computerthrough a user input device, generally indicated at 135 including butnot limited to a keyboard, keypad, touchscreen, jog shuttle, and apointing device, such as a mouse. Other input devices 135 may include amicrophone, an IR remote control, a track ball, a pen input device, ajoystick, a game pad, a digitizing tablet, a scanner, or the like. Theseand other input devices 135 are often connected to the processing unitthrough a serial port interface that is coupled to the system bus, butmay be connected by other interfaces, such as a parallel port, a gameport, a universal serial bus (“USB”), an IR interface, and/or variouswireless technologies. A monitor (e.g., display 115), or other type ofdisplay device, may also be connected to the system bus via aninterface, such as a video adapter. Visual output may also beaccomplished through a remote display network protocol such as RemoteDesktop Protocol, VNC, X-Window System, etc. In addition to visualoutput, a computer typically includes other peripheral output devices,such as speakers, printers, etc.

A display (in addition or in combination with display 115) can beemployed with processor 125 to present data that is electronicallyreceived from the processing unit. For example, the display can be anLCD, plasma, CRT, etc. monitor that presents data electronically.Alternatively or in addition, the display can present received data in ahard copy format such as a printer, facsimile, plotter etc. The displaycan present data in any color and can receive data from processor 125via any wireless or hard wire protocol and/or standard. In anotherexample, processor 125 and/or system 100 can be utilized with a mobiledevice such as a cellular phone, a smart phone, a tablet, a portablegaming device, a portable Internet browsing device, a Wi-Fi device, apersonal digital assistant (PDA), among others.

The computer can operate in a networked environment using logical and/orphysical connections to one or more remote computers, such as a remotecomputer(s). The remote computer(s) can be a workstation, a servercomputer, a router, a personal computer, microprocessor basedentertainment appliance, a peer device or other common network node, andtypically includes many or all of the elements described relative to thecomputer. The logical connections depicted include a local area network(LAN) and a wide area network (WAN). Such networking environments arecommonplace in offices, enterprise-wide computer networks, intranets andthe Internet.

When used in a LAN networking environment, the computer is connected tothe local network through a network interface or adapter. When used in aWAN networking environment, the computer typically includes a modem, oris connected to a communications server on the LAN, or has other meansfor establishing communications over the WAN, such as the Internet. In anetworked environment, program modules depicted relative to thecomputer, or portions thereof, may be stored in the remote memorystorage device. It will be appreciated that network connectionsdescribed herein are exemplary and other means of establishing acommunications link between the computers may be used.

Alternatively or in addition, a local or cloud (e.g., local, cloud,remote, among others) computing platform can be utilized for dataaggregation, processing, and delivery. For this purpose, the cloudcomputing platform can include a plurality of processors, memory, andservers in a particular remote location. Under a software-as-a-serviceparadigm, a single application is employed by a plurality of users toaccess data resident in the cloud. In this manner, processingrequirements at a local level are mitigated as data processing isgenerally done in the cloud, thereby relieving user network resources.The software-as-a-service application allows users to log into aweb-based service (e.g., via a web browser) which hosts all the programsresident in the cloud.

According to an embodiment, each power source 130 within system 100includes an onboard controller 200. Onboard controller may be anintegral component of power source 130 or be retro fit to existing powersources within a fleet F to provide the control methods describedherein. As best shown in FIG. 6, onboard controller 200 is connected tovarious components within the power source including the power circuit202 used in generating the power output and providing power output tothe implement 140. In an engine driven power source 130, onboardcontroller 200 is connected to the engine 178 or various componentsthereof to control operation of the engine including engine revolutionsper minute (RPM), combustion, idle, or other aspects of the engine tocontrol power output, emissions, noise levels or other characteristicsof the engine driven power supply that require control. The same is trueof a hybrid power source that includes an engine component 178 andenergy storage device 177. In the example shown in FIG. 6, connection tothe energy storage device 177 and engine component 178 is made throughpower circuit 202. As further shown in FIG. 6, onboard controller 200may be connected to additional components including an onboard inputdevice 204 that receives input from the user and an onboard output oronboard display 206 that provides information to user.

When retrofitting onboard controller 200 to an existing power source,onboard controller 200 may additionally be connected to other componentsor circuitry that perform control functions, such that onboardcontroller has the ability to select, limit, disable, or override thecontrol functions provided. For example, in a welding context, anexisting power supply may include a waveform generator 208 with alibrary or look up table of waveforms or welding modes that can begenerated by power source. As shown, wave form generator 208 may beprovided as part of power circuit 202. Onboard controller 200 may beconnected to the wave form generator 208 to limit the number ofwaveforms available, provide selected waveforms, or add additional waveform capability. It will be understood that other connections toexisting components and circuitry may be needed when retrofittingonboard controller 200 to an existing power source 130.

Onboard controller 200 may include an onboard data store 220 that canstore information, component change(s), and history associated withpower source 130 or data communicated from central controller 110. Forexample, the onboard data store 220 can store a date of configuration ofonboard controller 200, a time of configuration, a hardwareconfiguration of power source 130, a software version of onboardcontroller 200, a serial number and/or an identification of onboardcontroller 200, a welding program installed in the welding onboardcontroller 200 and/or a memory capacity of onboard controller 200. Theinformation stored in the power supply configuration data store 220 canfacilitate troubleshooting, servicing, operating, maintenance and/orupgrading of the welding power source 130.

Processor 125 can facilitate reconfiguration of onboard controller 200based, at least in part, upon information stored in the onboard datastore 220. For example, the processor 125 can facilitate sendinginformation (e.g., voltage setting(s), waveform(s) and/or currentsetting(s)) to onboard controller 200 to configure power source 130.Central controller 110 can also configure other parameters of powersource including operational parameters, such as operatingcharacteristics or features available to the user, limits on operationbased on emissions requirements, noise requirements, geographical limitsor other limits imposed by an agreement between the user and the owner,such as a rental/lease agreement or other conditions placed uponoperation by an external source. Examples of features include but arenot limited to modes of operation. In a welding context, these modes ofoperation may include selection of various waveforms or weldingprocesses, such as pulse or surface tension transfer (STT), gas metalarc welding (GMAW), flux cored arc welding, metal cored arc welding,submerged arc welding (SAW), narrow groove welding, gas tungsten arc(GTAW) welding, plasma arc welding, electron beam and laser welding,hard surfacing welding, arc gouging and/or manual shielded arc welding(SMAW).

The operational parameter may also include the available or configurablepower output of the power source. For example, a power source 130 may becapable of producing a power measured in amps, such as 500 amps. Centralcontroller 110 may, however, configure output of power source 130 to apower value less than the maximum power that power source 130 is capableof producing. In the 500 amp example, central controller 110 mayconfigure power source 130 to produce a maximum amperage of 100 amp, 300amp etc. In some instances, to deactivate power source, centralcontroller 110 may configure power source to produce 0 amp.

Onboard controller 200 may include an input output component 230. Inputoutput component 230 can receive input signal(s) from various sensors Sor other detecting or information providing components associated withpower source 130. For example, input output component 230 can receive aninput signal from a proximity switch indicating that a work piece WP isphysically present or operating environment conditions such astemperature, humidity, atmospheric pressure and the like from anappropriate sensor. Based at least in part upon information from theinput output component 230, onboard controller 200 can provide a poweroutput to an output port 212. Additionally, the input output component230 can send output signal(s) to central controller 110 viacommunications component 250.

With reference to FIG. 7, an accessory component 240 can controloperation of additional components associated with implement 140, suchas consumable delivery devices including but not limited to wirefeeders, gas or other fluid sources, and the like or accessories 242that are provided with power source 130 that are separate fromimplement, such as for example, an air compressor or pump provided withpower source 130. An accessory connector 244 may be provided on powersource 130 to attach an accessory 242 to power source, or in the case ofan onboard accessory 242, accessory connector 244 may provide aconnection to accessory such as for receipt of a conduit, cable, orhose, generally indicated at 245, used with accessory 242.

As discussed, onboard controller 200 includes a communications interface250 to facilitate communication with a remote system(s) including butnot limited to central controller 110. As shown in FIG. 6,communications interface 250 may be a wireless component thatcommunicates through various wireless protocols described herein or, asshown in FIG. 7, a wired component that receives a network cable 252 orthe like. Communication through either connection to the remote systemmay be made through a network 120 as discussed above.

Additional remote systems may include performance monitoring or otherdata tracking components that do not provide central controlfunctionality. For example, operating conditions, parameters, locationand other information associated or derived from data store 220 oronboard controller 200 may be communicated to a remote system(s) 255 fordata storage, aggregation or monitoring. In the example shown, remotesystem 255 is a portable computing device, such as a personal computer,such as a laptop, tablet or wearable computer, a smart phone or personaldigital assistant that allows remote monitoring of power source 130. Forexample, the communications interface 250 can retrieve informationstored in data store 220 and transmit the information to the remotesystem(s) 255 to facilitate troubleshooting, servicing, operating,maintenance and/or upgrading of the welding power supply 200. Byidentifying, for example, a time of configuration of the power source130, component change detail, and history of configuration of the powersource 130 to remote system 255, the communications interface 250 canenable to a supervisor or technician located in a remote physicallocation from power source 130 to monitor or troubleshoot power source130. As shown in FIG. 6, central controller 110 may be incorporated inremote system 255. As shown in FIG. 7, additional remote systems 255 maybe used to communicate with central controller 110 and reconfigure thepower source 130 as described above. In such instances, such additionalremote systems 255 would need authorization to access the centralcontroller's configuration functions. Alternatively, remote systems 255may not have the authority to configure or alter power source 130 andinstead have a read only type of function where access to informationfrom power source 130 or central controller 110 could be obtained viathe remote system 255 through network 120.

The communications interface 250 can be adapted for wired or wirelesscommunication utilizing any known local or global network includingcellular communications, Ethernet (IEEE 802.3), Wireless Ethernet (IEEE802.11), PPP (point-to-point protocol), point-to-multipoint short-rangeRF (Radio Frequency), WAP (Wireless Application Protocol), Bluetooth,IP, IPv6, TCP and User Datagram Protocol (UDP). Further, thecommunications interface 250 can communicate via an extranet and/or ashared private network. The communications interface 250 can utilizepost second generation mobile communications technology (e.g., 3G) tocommunicate with other device(s) (e.g., WAP gateway). The communicationsinterface 250 can include software that is reprogrammable. Thecommunications interface 250 can further communicate via one channeland/or shift among multiple channels, for example, depending on the typeof communication being performed (e.g., voice, data and/or high-speeddata). The communications interface 250 can further be adapted toutilize a particular communications modality based upon, for example,upon a priority level. Further, the communications interface 250 can beadapted to perform cognitive function(s) to facilitate communications.For example, the communications interface 250 can determine frequenciesavailable for communication (e.g., temporary use), determine cost(s)associated with communication on each of the frequencies, negotiateusage rights with the owner(s) of the channels. Additionally, thecommunications interface 250 can further monitor the quality oftransmission and/or receipt of information and adaptively modify thetransmission frequency. It is to be appreciated that the communicationsinterface 250 can include means for mobile communications that areembedded within power source 130 for example a printed circuit equippedwith a mobile communication chip set, and/or external to power source130, for example, a mobile phone serving as a mobile communication modemfor power source 130. In one implementation, the communicationsinterface 250 can be adapted for infrared communications utilizing, forexample, Infrared Data Association (IrDA) protocol(s). Thecommunications interface 250 can implement one or more of the IrDAprotocol layer(s): physical layer, link access protocol (IrLAP), linkmanagement protocol (IrLMP), information access service (IAS), tinytransport protocol (TinyTP), object exchange protocol (IrOBEX), serialand parallel port emulation (IrComm) and/or local area network access(IrLan).

At least one of the central controller 110, onboard controller 200, and,if used, remote component 255 may optionally include a securitycomponent 275. The security component 275 facilitates securecommunication between central controller 110, onboard controller and/orremote component 255. Given that welding information may be transferredover public networks such as the Internet, the security component 275can provide encrypted data communications along with authentication andauthorization services. Authentication refers to a determination that apurported user is whom they claim to be. Authorization is the process ofverifying that a user has been authorized by central controller 110 toaccess welding information. Encryption is the conversion of data into aform, such as a ciphertest, that is not easily understood byunauthorized agents. For example, authentication, authorization, andnon-repudiation may be established utilizing a Public Key Infrastructure(PKI) and X.509 Public Key Infrastructure Certificates to provideauthentication and message integrity. Further, a Secure Sockets Layer(SSL) and Secure HTTP (SHTTP) may be employed to provide authenticationand data encryption, wherein proprietary authentication andauthorization techniques may be employed utilizing either publiclyavailable encryption algorithms or those of custom design. Theseprotocols, with the exception of those based on a custom design, arereadily understood by those of ordinary skill in the art. They aredefined in specifications provided in the Request for Comments (RFC)documents from the Internet Engineering Task Force (IETF) and in othersources.

Negotiations can occur between the security component 275 of centralcontroller 110 and onboard controller 200. These negotiations may beutilized to establish a secure (e.g., encrypted) data channel, forexample, between the TCP/IP drivers of central controller 110 and powersource 130. Security component 275 may be housed on any of thecomponents within the system including at central controller 110 (FIG.6) or hosted on network 120 (FIG. 7). Security component 275 also may beused to establish appropriate authorization to perform control functionsthrough controller 110 i.e. configuring various parameters of powersource 130. This component 275 may also be used for authentication andverification of payment through a payment component 280, described morecompletely below.

Optionally, a payment component, generally indicated at 280, may beincorporated with power source 130 to allow a user to pay for changes inpower output, rental time, functionality, features, geographical scopeor other aspects that may require payment without leaving a work siteWS. As best shown, for example, in FIG. 6, power source 130 may belocated at a work site WS that is remote from the location where thepower source 130 was rented i.e. the rental site RS. In this instance,the central controller is operated by the rental agent at the rentalsite or other remote site RS and is remote from work site WS. The userobtains the power source 130 from remote site RS and transports it towork site WS to perform an operation 150, as shown. User pays a fee forrental of power source 130 with a selected configuration, but maydiscover once at the work site that the selected configuration needs tobe altered i.e. more time, functionality etc as described above. Thischange in functionality may require payment of an additional or reducedfee. If an additional fee is required, the user could use paymentcomponent 280 to make the payment remotely at work site WS. Centralcontroller 110, upon receiving verification and confirmation of payment,could then change the functionality of power source 130 remotely fromremote site RS.

Payment component 280 may include a card reader, scanner, cash receivingmachine or other device 281 (FIG. 6) that processes a payment token 282,such as a credit card, debit card, gift card, QR code, bar code, RFIDchip, magnetic strip, or cash. Alternatively, payment component 280 canbe incorporated into controller 200, such that the user may chargepayment to an account. In this instance, as shown in FIG. 7, paymentcomponent 280 may be accessed through an input component 204 associatedwith onboard controller 200, such as a keypad, touch screen, and thelike. In either instance, payment component 280 is in communication withthe network 120 for purposes of processing payment using third partyvendors or through the owner of the power source directly. Paymentprocessing and verification may be communicated to central controller110 to allow an alteration of an operating parameter as described above.For example, a power source 130 having an overall power output capacityof 500 amps may be rented for use at a 300 amp level. The user decidesthat operation at the 500 amp level is needed. User communicates theneed for the additional power to central controller 110 through onboardcontroller 200 of alternate communications means including but notlimited to accessing central controller 110 via the internet or othercommunication network 120. In turn, central controller 110 communicatesa price for the additional power output and accepts payment via paymentcomponent 280. Upon confirming payment, central controller 110communicates a command to onboard controller 200 to increase theavailable power from 300 amp to 500 amp.

With reference to FIG. 2, a power source system includes plural powersources that form a fleet F of power sources 130 that are incommunication with a central controller 110. Communication may occur viaa network 120. Power sources may reside at a location that coincideswith the location of central controller 110 at the time of purchase orrental, and then be moved to a work site WS where an operation isperformed using power source 130. Each power source 130 in fleet F maybe deployed to one work site WS or to different work sites as needed.

Various components of the system 100 have been described with referenceto multiple embodiments depicted in the figures. It will be understoodthat these components and structures shown in the figures may beinterchanged or substituted amongst the depicted embodiments, which arenot limiting.

FIGS. 8 and 9 illustrate a methodology for providing various aspectsincluding providing configuration information to one or more powersources 130 located remotely from a central controller 110. Referencewill be made to components described above and depicted in FIGS. 1-7.The method comprises a group of actions or processes represented byblocks. While, for purposes of simplicity of explanation, themethodology is shown and described as a series of blocks, it is to beunderstood and appreciated that the present invention is not limited bythe number or order of blocks, as some blocks may, in accordance withthe present invention, occur in different orders and/or concurrentlywith other blocks from that shown and described herein. For example,those skilled in the art will understand and appreciate that amethodology could alternatively be represented as a series ofinterrelated states, such as in a state diagram. Moreover, not allillustrated acts may be required to implement a methodology inaccordance with the present invention.

In accordance with an embodiment, a method 800 includes providing aprocessor 125 in communication with a communications interface 250 at810. The method includes providing a computer-readable storage medium126 that stores computer-executable instructions thereon at 820. Theprocessor 125 is configured to receive via the communications interface250 operational information from an onboard controller 200 of a powersource 130 at 830. The processor 125 is adapted to configure one or moreparameters of the processor 125. For example, at 840, processor 125communicates a signal to onboard controller 200 to alter an operatingstate of power source 130. As shown at 850, alteration of the operatingstate of power source 130 is based at least in part upon operationalinformation. The operating state may include a parameter such as theconfigurable power output of power source, an engine operating limit,and an accessory operating limit of each power source based on thegeographic based alert information

According to another embodiment, at 860, set a maximum available poweroutput of the associated power source to a configured output level thatis less than the maximum power output. For example, a power source 130with a maximum power output of 500 amp may be configured by a signalfrom processor 125 to a configurable output power of 300 amp for aselected operation, and so configured, the method includes performing anoperation on the workpiece WP. If the power source 130 had beenpreviously configured at a lower level, signal may set an increasedpower output level compared to the current configured level. Once thepower source is configured, the method includes performing an operationon a work piece, for example, welding, cutting, heating etc in a weldingcontext or mixing in a cement mixing context. In a vehicle context, theoperation may include operating the vehicle i.e. moving the vehicle.

According to another embodiment, at 870, the signal deactivates thepower source or power to the implement attached to the power source. Inone example, the method includes a signal from processor 125 on centralcontroller 110 to configure onboard controller 200 to deactivate thepower source or to stop operation on a workpiece WP 890. For example, ina rental context, such a signal may be sent when a maximum usage limitor time limit has been reached or if the user attempts to move the powersource 130 outside of a permitted geographical area.

According to another embodiment, controller 110 tracks operationalinformation including the parameters discussed above and operatinglimits that may be imposed by the rental agreement, legal restrictions,safety considerations, or other similar limits. For example, in a rentalcontext, an operating limit includes an operating geographical area ordistance from a location, maximum operating time, maximum check outtime, maximum power output, permitted power delivery modes, which may beimposed by agreement, emissions limits, noise limits etc. In oneembodiment, processor 125 of controller 110 is programmed to communicatewith onboard controller 200 to obtain operational information fromonboard controller 200 including but not limited to time of operation,the configurable power output maximum, geographic location, configurablepower delivery modes and the like. According to the method 900, centralcontroller 110 may obtain operating limits from a source at 930;communicate with one or more power source 130 or its onboard controller200 at 940 to obtain current operational information; and optionallyperform a calculating step to obtain secondary operating information at950. For example, central controller 110 may subtract time when thepower source is on but no operation is occurring to determine the idletime versus the active time. According to another example, the centralcontroller 110 may use the geographic location of the power source 130to determine distance from a particular location or region or distancefrom a source. According to another example, central controller maycalculate emissions or noise output based on engine speed or otherengine operating conditions. Alternatively, any of the calculating stepsmay be performed by onboard controller 200 and simply reported tocentral controller 110 through the communications step.

The operational information obtained from power source 130 or calculatedoperational information is then compared at 960 to operating limitsobtained at 930. If operational limits are exceeded or alteration of theoperation of one or more power source 130 is needed, central controller110 sends a signal to power source 130 or its associated onboardcontroller 200 to alter an operating state of the power source 130 at970.

Operational limits obtained at 930 may be stored in data store andinclude preprogrammed operating limits such as those set up in a rentalagreement, terms of use etc. For example as shown, these may includedistance, time of operation, power output maximum level, permitted modesof power delivery and the like. According to an embodiment, centralcontroller 110 may communicate with a data source to obtain additionaloperating limits including, for example, ozone alerts, emissions limits,noise restrictions and the like that may limit operation of a powersource. The comparison step may include referencing both user providedoperating limits 920 or external operating limits obtained from anexternal data source 910. For example, based on the engine operatinginformation and geographic location, central controller may send asignal to limit engine operation based on an ozone alert, noiserestriction, or emissions restriction imposed on the geographic area 915where the power source is located. User inputs may include, for example,limits imposed by an agreement or terms of use 925 including but notlimited to distance, time of operation, power output, and permittedpower delivery modes, such as wave forms, pulse functions and the like.

What has been described above are various aspects of the presentinvention. It is, of course, not possible to describe every conceivablecombination of components or methodologies for purposes of describingthe present invention, but one of ordinary skill in the art willrecognize that many further combinations and permutations of the presentinvention are possible. Accordingly, the present invention is intendedto embrace all such alterations, modifications and variations that fallwithin the spirit and scope of the appended claims.

In accordance with one embodiment a power source system includes pluralpower sources, wherein each of the plural power sources is adapted toprovide a configurable power output to an implement, and wherein each ofthe plural power sources has an onboard controller; a central controllerthat is remote from the plural power sources; the central controllerbeing in communication with respective onboard controllers via one ormore networks, the central controller being adapted to communicate asignal to at least one onboard controller to selectively alter anoperating condition of an associated power source. In one example, thesignal instructs the onboard controller to deactivate power to theimplement or deactivate the associated power source to prevent operationthereof. In another example, the signal configures the onboardcontroller to set a maximum available power output of the associatedpower source to a configured output level. The configured output levelmay be a selected amperage, voltage, wattage or other unit ofmeasurement commonly referred to in a given application or industry. Forexample, in a welding application it is common to refer to power interms of an amperage. For example, the configurable power may beexpressed as 100 amp, 300 amp, 500 amp and so on. These values areprovided as examples. It will be understood that any value between 0 andthe maximum available power for a given power source may be used.

According to another exemplary embodiment, the onboard controller isadapted to monitor an emission level of the associated power source andcommunicate emission information to the central controller; and whereinthe central controller receives the emission information from theonboard controller and a maximum available power output of theassociated power source based on the emission information received.

According to another exemplary embodiment the implement is a weldingtorch. In another exemplary embodiment, the implement is a cuttingtorch.

According to another exemplary embodiment at least one of the pluralpower sources includes an accessory, and wherein the operating conditionincludes an activation state of the accessory.

According to another exemplary embodiment, the onboard controllerincludes a sensor that tracks a limiting condition and communicates avalue of the limiting condition to the central controller, and whereinupon detection of the value of the limiting condition reaching aselected limit, the central controller alters the operating condition.According to a further example, the limiting condition includes at leastone of an operating time limit, a geographical limit, an emissionslimit, a pollution limit, a noise limit, a network connectivity limit,and a time limit.

Another exemplary embodiment includes power source system includingpower source in communication with a power source network, wherein eachof power source in the network has an active mode where power isprovided to an implement and an idle mode where no power is beingprovided to the implement; a central controller in communication withthe power source network, the central controller being remote from thepower source and in communication with the power source via the powersource network, wherein the central controller monitors a time period ofoperation for the power source, wherein the time period of operationincludes active mode time but excludes idle mode time, and wherein thecentral controller deactivates the power source when a respective timeperiod of operation exceeds an authorized period of operation.

According to another exemplary embodiment, the implement is a weldingtorch.

According to another exemplary embodiment, the central controllercalculates a charge based on the time period of operation. According toa further embodiment, the power source includes a payment component,wherein the central controller communicates with the payment componentand wherein the central controller includes a maximum period ofoperation for each of the plural power sources and deactivates aselected power source when the time period of operation is reached.According to a further example, the central controller is adapted toallocate an additional maximum period of operation or an extension ofthe maximum period of operation upon receiving a selected payment fromthe means for payment.

Another exemplary embodiment includes power source system including aprocessor; a communications interface; and a computer-readable storagemedium having stored thereon computer-executable instructions that, whenexecuted by the processor, configure the processor to: receive, via thecommunications interface, operational information from an onboardcontroller of a power source adapted to provide a configurable poweroutput to an implement; and communicate a signal to the onboardcontroller to alter an operating state of the power source based atleast in part on the operational information. According to on example,the signal instructs the onboard controller to deactivate power to theimplement or deactivate the associated power source to prevent operationthereof. According to another example, the signal configures the onboardcontroller to set a maximum available power output of the associatedpower source to a configured output level.

Another exemplary embodiment includes power source system includingplural power sources, wherein each of the plural power sources isadapted to provide a configurable power output to an implement, andwherein each of the plural power sources has an onboard controller; acentral controller that is remote from the plural power sources and incommunication with each power source, wherein the central controllertracks a location of each of the plural power sources and wherein thecentral controller receives geographic based alert information; whereinthe central controller sets a parameter including at least one of theconfigurable power output, an engine operating limit, and an accessoryoperating limit of each power source based on the geographic based alertinformation. According to one example, the geographic based alertinformation includes ozone action alerts. According to another example,the geographic based alert information includes a noise restriction.According to a further example, the geographic based alert includes apermitted geography limit.

These and other objects of this invention will be evident when viewed inlight of the drawings, detailed description and appended claims.

The subject innovation can be used with any suitable engine-drivenwelder, engine-driven welding system, engine-driven welding apparatus, awelding system powered by an engine, a welding system powered by anenergy storage device, others not expressly listed, and/or combinationsthereof. It is to be appreciated that any suitable system, device, orapparatus that can perform a welding operation can be used with thesubject innovation and such can be chosen with sound engineeringjudgment without departing from the intended scope of coverage of theembodiments of the subject invention. The engine driven welder caninclude a power source that can be used in a variety of applicationswhere outlet power is not available or when outlet power will not berelied on as the sole source of power including portable powergeneration, backup power generation, heating, plasma cutting, welding,and gouging. The example discussed herein relates to welding operations,such as arc welding, plasma cutting, and gouging operations. It is to beappreciated that a power source can generate a portion of power, whereinthe portion of power is electrical power. It is to be appreciated that“power source” as used herein can include a motor, an engine, agenerator, an energy storage device, a component that creates electricalpower, a component that converts kinetic energy into electrical power,or a combination thereof. By way of example and not limitation, FIGS.1-4 illustrate welding systems or devices that can be utilized with thesubject innovation. It is to be appreciated that the following weldingsystems are described for exemplary purposes only and are not limitingon the welding systems that can utilize the subject innovation orvariations thereof.

What is claimed is:
 1. A power source system, comprising: a processor; acommunications interface; and a computer-readable storage medium havingstored thereon computer executable instructions that, when executed bythe processor, configure the processor to: receive, via thecommunications interface, operational information from an onboardcontroller of a power source adapted to provide a configurable poweroutput to an implement; receive, via the communications interface,payment information concerning at least one of a pump and a compressorof the power source; and communicate a signal to the onboard controllerto enable operation of the at least one of the pump and the compressorof the power source based at least in part on the payment information.2. The system of claim 1, wherein the onboard controller is adapted tomonitor an internal combustion engine emission level of the power sourceand communicate emission information to the processor; and wherein theprocessor receives the emission information from the onboard controllerand a maximum available power output of the power source based on theemission information received.
 3. The system of claim 1, wherein theimplement is a welding torch.
 4. The system of claim 1, wherein theimplement is a cutting torch.
 5. The system of claim 1, wherein theprocessor communicates another signal to the onboard controller thatinstructs the onboard controller to alter a maximum welding amperagelevel of the power source.
 6. The system of claim 1, wherein the onboardcontroller includes a sensor that tracks a limiting condition andcommunicates a value of the limiting condition to the processor, andwherein upon detection of the value of the limiting condition reaching aselected limit, the processor alters an operating state of the powersource.
 7. The system of claim 6, wherein the limiting conditionincludes at least one of an operating time limit, a pollution limit, anoise limit, and a network connectivity limit.
 8. The system of claim 1,wherein the processor calculates a charge based on a time period ofoperation of the power source.
 9. The system of claim 1, wherein thepower source includes a payment component, wherein the processorcommunicates with the payment component and wherein the processorincludes a maximum period of operation for the power source anddeactivates the power source when the maximum period of operation isreached.
 10. The system of claim 9, wherein the processor is adapted toallocate an additional maximum period of operation or an extension ofthe maximum period of operation upon receiving a selected payment fromthe payment component.
 11. The system of claim 1, wherein the processorcommunicates another signal to the onboard controller that instructs theonboard controller to at least one of deactivate power to the implementor deactivate the power source to prevent operation thereof.
 12. Thesystem of claim 1, wherein the processor communicates another signal tothe onboard controller that configures the onboard controller to set amaximum available power output of the power source to a configuredoutput level.
 13. A power source system, comprising: a processor; acommunications interface; and a computer-readable storage medium havingstored thereon computer executable instructions that, when executed bythe processor, configure the processor to: receive, via thecommunications interface, operational information from an onboardcontroller of a power source adapted to provide a configurable poweroutput to an implement; and communicate a signal to the onboardcontroller to alter an operating state of the power source based atleast in part on the operational information, wherein the operationalinformation is an ozone alert.